U.S. patent application number 13/493119 was filed with the patent office on 2012-12-13 for process of managed ecosystem fermentation.
Invention is credited to Edward Arthur Calt, JR., Stanley Sylvester Toporek, Herbert Graham Tull, IV.
Application Number | 20120316320 13/493119 |
Document ID | / |
Family ID | 47293698 |
Filed Date | 2012-12-13 |
United States Patent
Application |
20120316320 |
Kind Code |
A1 |
Calt, JR.; Edward Arthur ;
et al. |
December 13, 2012 |
PROCESS OF MANAGED ECOSYSTEM FERMENTATION
Abstract
The presently disclosed subject matter relates to Managed
Ecosystem Fermentation (MEF) which is a continuous microbial
process utilizing a managed ecosystem approach employing dozens to
thousands of species of microorganisms, occurring in a controlled
artificial environment and consuming organic materials without
benefit of sterilization. The process of utilizing this
fermentation for the consumption of organic materials on a
continuous basis is within the scope of this disclosed subject
matter. The process of separating chemicals as industrial chemicals
from this fermentation on a continuous basis is within the scope of
this disclosed subject matter. The process of separating biomass
useful as high protein animal feed or fertilizer from this
fermentation on a continuous (or semi-continuous) basis is within
the scope of this disclosed subject matter.
Inventors: |
Calt, JR.; Edward Arthur;
(Raleigh, NC) ; Tull, IV; Herbert Graham; (Cary,
NC) ; Toporek; Stanley Sylvester; (Raleigh,
NC) |
Family ID: |
47293698 |
Appl. No.: |
13/493119 |
Filed: |
June 11, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61495183 |
Jun 9, 2011 |
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Current U.S.
Class: |
530/350 ;
435/106; 435/115; 435/134; 435/136; 435/140; 435/141; 435/160;
435/161; 435/167; 435/168; 435/183; 435/201; 435/209; 435/294.1;
435/70.3; 554/1; 562/606 |
Current CPC
Class: |
C12P 7/52 20130101; C12P
7/56 20130101; C12P 39/00 20130101; Y02P 20/145 20151101; Y02W
30/40 20150501; Y02A 40/212 20180101; C05F 11/00 20130101; C12N
1/00 20130101; Y02E 50/17 20130101; Y02E 50/343 20130101; Y02A
40/20 20180101; Y02W 30/47 20150501; Y02A 40/201 20180101; Y02W
30/43 20150501; C12P 7/20 20130101; Y02E 50/13 20130101; C05F 1/007
20130101; C05F 9/00 20130101; C05F 5/008 20130101; C12P 5/023
20130101; Y02A 40/214 20180101; C12M 21/04 20130101; Y02E 50/30
20130101; C05F 17/50 20200101; C02F 11/04 20130101; C12P 7/54
20130101; C05F 17/10 20200101; C12M 43/08 20130101; C12P 7/40
20130101; C12M 45/02 20130101; Y02E 50/10 20130101 |
Class at
Publication: |
530/350 ;
435/134; 435/140; 435/141; 435/136; 435/70.3; 435/161; 435/183;
435/209; 435/201; 435/167; 435/168; 435/160; 435/106; 435/115;
435/294.1; 554/1; 562/606 |
International
Class: |
C07K 14/00 20060101
C07K014/00; C12P 7/54 20060101 C12P007/54; C12P 7/52 20060101
C12P007/52; C12P 7/40 20060101 C12P007/40; C12P 21/00 20060101
C12P021/00; C12P 7/06 20060101 C12P007/06; C12N 9/00 20060101
C12N009/00; C12N 9/42 20060101 C12N009/42; C12N 9/26 20060101
C12N009/26; C12P 5/02 20060101 C12P005/02; C12P 3/00 20060101
C12P003/00; C12P 7/16 20060101 C12P007/16; C12P 13/04 20060101
C12P013/04; C12P 13/08 20060101 C12P013/08; C12M 1/02 20060101
C12M001/02; C11B 13/00 20060101 C11B013/00; C07C 53/124 20060101
C07C053/124; C12P 7/64 20060101 C12P007/64 |
Claims
1. A method for generating resources from feedstocks, the method
comprising: receiving an organic feedstock and a rumen in a
fermenter; and fermenting the organic feedstock with the rumen to
generate a resource.
2. The method of claim 1, wherein the organic feedstock comprises
catering waste, biodiesel waste, agricultural waste, food
processing plant waste, wood pulp, shredded paper, paper mill
sludge, cotton gin waste, sewage sludge, slaughter house waste,
organic fraction of municipal solid waste (OFMSW), or algae, or
combinations thereof.
3. The method of claim 1, wherein the rumen comprises a rumen from
a ruminant animal, a bovine rumen, a sheep rumen, a goat rumen, a
deer rumen, or a bison rumen, or combinations thereof.
4. The method of claim 1, wherein the resource generated comprises
one or more of chemicals, lipids, volatile fatty acids, long chain
fatty acids, acetic acid, proprionic acid, isobutyric acid, butyric
acid, isovaleric acid, valeric acid, lactic acid, hexanoic acid,
biomass, high protein animal feed, fertilizer, phosphate
fertilizer, nitrogen fertilizer, proteins, amino acids, lysine,
enzymes, cellulase, alpha-amylase, histidase, lysozyme, penicillin
acylase, ethanol, butanol, biogas, methane, hydrogen, carbon
dioxide, and water.
5. The method of claim 1, comprising removing a portion of the
chemicals that are acidic to maintain the fermenting in a pH range
between about pH 4 to about pH 9.
6. The method of claim 5, wherein the acidic chemicals comprise
VFAs.
7. The method of claim 1, comprising fractionating one or more of
the resources, wherein the resources are selected from the group
consisting of lipids, chemicals, biogas, and biomass.
8. The method of claim 1, comprising adding a microorganism, a
bacteria, a butyric acid producing bacteria, a cellulosic bacteria,
a Clostridium acetobutylicium, a yeast, an industrial yeast, a
brewer's yeast, a Trichoderma reesei, a fungi, a protozoa, earth
worm microbes, termite microbes, cecum microbes, rabbit cecum
microbes, or horse cecum microbes, or combinations thereof.
9. The method of claim 1, wherein the resource comprises chemicals,
and the method comprising separating one or more of the chemicals
in a chemical separation unit.
10. The method of claim 9, wherein the chemicals comprise one or
more of volatile fatty acids, long chain fatty acids, acetic acid,
proprionic acid, isobutyric acid, butyric acid, isovaleric acid,
valeric acid, lactic acid, or hexanoic acid, and wherein the
chemical separation unit comprises an ion exchange technology.
11. The method of claim 1, wherein the resource comprises chemicals
and the method comprising: shunting at least a portion of the
chemicals to a biogas generator, wherein the biogas generator is a
second fermenter that comprises the rumen; and fermenting the
chemicals and the rumen in the biogas generator to generate
biogas.
12. The method of claim 1, wherein the resource comprises biomass,
the method comprising: one of fractionating and separating the
biomass through particulate separation; and dewatering the
biomass.
13. The method of claim 12, wherein the organic feedstock is an
adulterated feedstock and wherein the dewatered biomass is a soil
enhancer having live microbes.
14. The method of claim 12, comprising drying the dewatered
biomass.
15. The method of claim 14, wherein the organic feedstock is a feed
grade feedstock and wherein the dewatered and dried biomass is a
high protein animal feed (HPAF).
16. The method of claim 14, wherein the organic feedstock is an
adulterated feedstock and wherein the dewatered and dried biomass
is a dry fertilizer.
17. The method of claim 1, wherein the fermenting is performed
under non-sterile conditions.
18. The method of claim 1, wherein the rumen comprises bovine
rumen.
19. The method of claim 18, comprising adding a butyric acid
producing bacteria.
20. The method of claim 1, wherein the resource comprises lipids,
chemicals, biomass, and biogas, the method comprising: one of
fractionating and separating through particulate separation the
resource lipids, chemicals, biomass, and biogas; and producing one
or more of a chemical product, a lipid product, a biogas, a biomass
product, a fertilizer, a high protein animal feed, a soil enhancer
with live microbes, acetic acid, proprionic acid, isobutyric acid,
butyric acid, isovaleric acid, valeric acid, lactic acid, or
hexanoic acid, or combinations thereof.
21. A system for generating resources from organic feedstocks, the
system comprising: a grinder/mixer configured to receive an organic
feedstock and a rumen; and a fermenter configured to receive the
organic feedstock and the rumen and configured to ferment the
organic feedstock to generate a resource.
22. The system of claim 21, wherein the organic feedstock comprises
catering waste, biodiesel waste, agricultural waste, food
processing plant waste, wood pulp, shredded paper, paper mill
sludge, cotton gin waste, sewage sludge, slaughter house waste,
organic fraction of municipal solid waste (OFMSW), or algae, or
combinations thereof.
23. The system of claim 21, wherein the fermenter is configured to
generate the resource comprising one or more of chemicals, lipids,
volatile fatty acids, long chain fatty acids, acetic acid,
proprionic acid, isobutyric acid, butyric acid, isovaleric acid,
valeric acid, lactic acid, hexanoic acid, biomass, high protein
animal feed, fertilizer, phosphate fertilizer, nitrogen fertilizer,
proteins, amino acids, lysine, enzymes, cellulase, alpha-amylase,
histidase, lysozyme, penicillin acylase, ethanol, butanol, biogas,
methane, hydrogen, carbon dioxide, and water.
24. The system of claim 21, wherein the rumen comprises a rumen
from a ruminant animal, a bovine rumen, a sheep rumen, a goat
rumen, a deer rumen, or a bison rumen, or combinations thereof.
25. The system of claim 21, wherein the grinder/mixer is configured
to receive a microorganism, a bacteria, a butyric acid producing
bacteria, a cellulosic bacteria, a Clostridium acetobutylicium
bacteria, a yeast, an industrial yeast, a brewer's yeast, a
Trichoderma reesei, a fungi, a protozoa, earth worm microbes,
termite microbes, cecum microbes, rabbit cecum microbes, or horse
cecum microbes, or combinations thereof.
26. The system of claim 21, wherein the resource comprises
chemicals and wherein the fermenter is configured for removal of a
portion of the chemicals that are acidic to maintain the pH in a
range between about pH 4 to about pH 9.
27. The system of claim 21, wherein the fermenter is configured to
fractionate one or more of the resources selected from the group
consisting of lipids, chemicals, biogas, and biomass.
28. The system of claim 21, wherein the resource comprises
chemicals, the system comprising a chemical separation unit
configured to separate one or more of the chemicals.
29. The system of claim 28, wherein the chemicals comprise one or
more of volatile fatty acids, long chain fatty acids, acetic acid,
proprionic acid, isobutyric acid, butyric acid, isovaleric acid,
valeric acid, lactic acid, or hexanoic acid, and wherein the
chemical separation unit comprises an ion exchange technology.
30. The system of claim 21, wherein the resource comprises
chemicals, the system comprising: a biogas generator configured as
a second fermenter to receive the rumen and at least a portion of
the chemicals to utilize to generate biogas.
31. The system of claim 21, wherein the system is configured to be
operated under non-sterile conditions.
32. The system of claim 21, wherein the rumen comprises bovine
rumen.
33. The system of claim 32, wherein the mixer/grinder is configured
to receive addition of a butyric acid producing bacteria.
34. The system of claim 21, wherein the resource comprises
chemicals, biomass, lipids, and biogas, the system comprising: the
fermenter configured to fractionate the resource chemicals,
biomass, lipids, and biogas; a chemical separation unit configured
to generate a chemical product; and a biomass separation unit
configured to generate a biomass product.
35. The system of claim 34, comprising a biogas generator
configured to generate biogas from at least a portion of the
chemicals.
36. The system of claim 34, wherein the chemical product comprises
an acetic acid, a proprionic acid, a isobutyric acid, a butyric
acid, an isovaleric acid, a valeric acid, a lactic acid, or a
hexanoic acid, or combinations thereof.
37. The system of claim 34, wherein the biomass product is selected
from the group consisting of a fertilizer, a high protein animal
feed, and a soil enhancer having live microbes.
38. The system of claim 34, comprising a power generation and heat
recovery unit configured to generate power and heat, wherein one of
the generated power and heat are utilized in the system.
39. (canceled)
40. The method of claim 1, wherein the resource comprises biomass,
the method comprising: fractionating and separating the biomass
through particulate separation; and dewatering the biomass.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional
application No. 61/495,183, filed Jun. 9, 2011, the disclosure of
which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The presently disclosed subject matter relates to a process
for managed ecosystem fermentation (MEF) of organic feedstocks to
produce industrial chemical and biomass products.
BACKGROUND
[0003] Microbial ecosystems are found naturally in many places,
including the digestive tracts of most animals. The starting point
of this process is the microbial fauna found in the rumen organ of
cattle and other ruminant animals. These natural microbial
ecosystems are continuous processes and do not require sterilized
feedstocks. However, natural microbial ecosystems found in animals
are size limited by the host organism, are not actively managed to
modulate the output materials, and cannot support extracting large
volumes of chemicals or biomass for industrial purposes without
detriment to the host animal.
[0004] Microbial ecosystems are also found in artificial
environments, such as anaerobic digesters and activated sludge type
waste water treatment plants. These installations can scale to
large sizes but do not actively manage the mix of species within
their microbial ecosystems, nor do they recover both chemicals and
biomass for use in industrial products.
[0005] Accordingly, a need for replicating microbial ecosystems
exists that addresses these and other issues associated with the
prior art.
SUMMARY
[0006] This Summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the Detailed Description. This Summary is not intended to identify
key features or essential features of the claimed subject matter,
nor is it intended to be used to limit the scope of the claimed
subject matter.
[0007] In one embodiment of the presently disclosed subject matter,
a method is provided for generating resources from feedstocks, the
method comprising fermenting an organic feedstock with a rumen to
generate a resource. The organic feedstock comprises one or more of
catering waste, biodiesel waste, agricultural waste, food
processing plant waste, wood pulp, paper mill sludge, cotton gin
waste, sewage sludge, slaughter house waste, organic fraction of
municipal solid waste (OFMSW), or algae. The rumen comprises a
rumen from a ruminant animal. The resources generated comprise one
or more of chemicals, volatile fatty acids, long chain fatty acids,
lipids, high protein animal feed, fertilizer, amino acids, enzymes,
ethanol, butanol, biogas, or water.
[0008] In one embodiment of the method, the resource comprises
chemicals and the method comprises shunting at least a portion of
the chemicals to a biogas generator, wherein the biogas generator
is a second fermenter that comprises the rumen; and fermenting the
chemicals and the rumen in the biogas generator to generate
biogas.
[0009] In one embodiment, the method comprises utilizing at least a
portion of the generated resource chemicals, the generated resource
hydrogen, and/or the generated resource biogas to generate power
and/or heat for the method.
[0010] In one embodiment, the method comprises reclaiming at least
a portion of the generated resource water.
[0011] In one embodiment, the method comprises adding one or more
of a microorganism, a bacteria, a butyric acid producing bacteria,
a cellulosic bacteria, a yeast, a fungi, a protozoa, earth worm
microbes, termite microbes, or cecum microbes.
[0012] In one embodiment of the presently disclosed subject matter,
a system is provided for generating resources from organic
feedstocks, the system comprising a grinder/mixer configured to
receive an organic feedstock and a rumen, and a fermenter
configured to receive the organic feedstock and the rumen and
configured to ferment the organic feedstock to generate a resource.
The resources generated comprise one or more of chemicals, volatile
fatty acids, long chain fatty acids, lipids, high protein animal
feed, fertilizer, amino acids, enzymes, ethanol, butanol, biogas,
or water.
[0013] In one embodiment of the system, the fermenter is configured
to fractionate the generated resource lipids, chemicals, biogas,
and biomass; and the system comprises a lipid separation unit
configured to generate a lipid product; a chemical separation unit
configured to generate a chemical product; a biomass separation
unit configured to generate a biomass product; and a biogas
generator configured to generate biogas from at least a portion of
the generated resource chemicals.
[0014] In one embodiment, the chemical product comprises one or
more of an acetic acid, a proprionic acid, an isobutyric acid, a
butyric acid, an isovaleric acid, a valeric acid, a lactic acid, or
a hexanoic acid.
[0015] In one embodiment, the biomass product is selected from the
group consisting of a fertilizer, a high protein animal feed, and a
soil enhancer having live microbes.
[0016] In one embodiment, the feedstock comprises algae and the
lipid product is the lipid from the algae.
[0017] In one embodiment, the system comprises a power generation
and heat recovery unit configured to generate power and/or heat,
wherein the generated power and/or heat are utilized in the
system.
[0018] In one embodiment, the system comprises a remote facility
configured to monitor and/or control the fermenter through use of a
communications link between the remote facility and the
fermenter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows a comparison of a traditional anaerobic
digester and a Managed Ecosystem Fermentation (MEF) train for
generating resources including metabolites, biomass products,
biogas, and electricity from fermentation of waste feedstocks.
[0020] FIG. 2 is a flow diagram illustrating a Managed Ecosystem
Fermentation (MEF) train for generating resources including
chemical products, biomass products, biogas, power and heat, and
reclaimed water from fermentation of organic feedstocks with rumen.
The MEF train allows for stirring or agitation of the fermenter and
separation of the chemicals and biomass in a particulate separation
unit.
[0021] FIG. 3 is a flow diagram illustrating a Managed Ecosystem
Fermentation (MEF) train for generating resources including
chemical products, lipid products, biomass products, biogas, power
and heat, and reclaimed water from fermentation of organic
feedstocks with rumen. The MEF train allows for fractionation of
the lipids, chemicals, biomass, and biogas from the fermenter.
[0022] FIG. 4 is the same flow diagram as depicted in FIG. 3 except
that it shows the use of adulterated feedstock to generate biomass
to produce a soil enhancer having live microbes.
[0023] FIG. 5 is the same flow diagram as depicted in FIG. 4 with
the addition that it shows the use of feed grade feedstock to
generate biomass that is dewatered and dried to produce High
Protein Animal Feed (HPAF).
[0024] FIG. 6 is the same flow diagram as depicted in FIG. 5 except
that it shows the use of adulterated feedstock to generate biomass
that is dewatered and dried to produce dry fertilizer.
[0025] FIG. 7 is a flow diagram illustrating a Managed Ecosystem
Fermentation (MEF) train. In the MEF train, the metabolites and
microbial mass produced by fermentation of the feedstock by
microbes are recovered as biomass products, metabolite (chemical)
products, and reclaimed water.
[0026] FIG. 8 is a flow diagram illustrating a cascade filter unit
comprising a set of membranes arranged in order of descending pore
size. The first screens are for retaining the larger pieces of
digesta for return to the fermentation system. The later screens
enable separation between the biomass and the metabolites
(chemicals) extracted from the fermentation.
[0027] FIG. 9 is a flow diagram illustrating a Managed Ecosystem
Fermentation (MEF) train for conversion of a feed grade feedstock
to biomass that is dewatered and dried to produce High Protein
Animal Feed (HPAF).
[0028] FIG. 10 is a flow diagram illustrating a Managed Ecosystem
Fermentation (MEF) train for conversion of an adulterated organic
waste feedstock to biomass that is dewatered and dried to produce a
dried fertilizer with high levels of organics, nitrates, and
phosphates.
[0029] FIG. 11 is a flow diagram illustrating a Managed Ecosystem
Fermentation (MEF) train for conversion of an adulterated organic
waste feedstock to biomass that is partially dewatered to produce a
soil enhancer product having living microbes to supplement the
microbes that are found natively in soils.
[0030] FIG. 12 is a flow diagram illustrating the separation of
different protein species using a series of capture units.
[0031] FIG. 13 is a flow diagram illustrating initial,
intermediate, and final products that are generated by the Managed
Ecosystem Fermentation (MEF) process described herein.
[0032] FIG. 14 is a flow diagram illustrating initial products that
are generated by the Managed Ecosystem Fermentation (MEF) process
described herein.
[0033] FIG. 15 is a graph showing the presence and daily
fluctuation (over a 30 day period) in the liquid layer of an MEF of
each of the VFAs: acetic acid, butyric acid, valeric acid, and
hexanoic acid as a percent, as well as the percent total of these 4
VFAs.
[0034] FIG. 16 is a graph showing the daily fluctuation in pH
(circle symbols) and percent total of the 4 VFAs acetic acid,
butyric acid, valeric acid, and hexanoic acid (square symbols)
measured in the liquid layer of an MEF over a 30 day period.
[0035] FIG. 17 is a graph showing the daily percent of each of the
VFAs acetic acid, butyric acid, valeric acid, and hexanoic acid as
well as the daily percent of the total of these 4 VFAs for an MEF
with daily pH adjustment within a range 5.9-6.1.
[0036] FIG. 18 is a graph showing total percent of the 4 VFAs
acetic acid, butyric acid, valeric acid, and hexanoic acid in a
control MEF (line with triangles) and an MEF with added biodiesel
waste (line with squares).
DETAILED DESCRIPTION
[0037] The presently disclosed subject matter provides methods for
generating resources from feedstocks. More specifically, the
methods provided herein comprise fermenting an organic feedstock
with a rumen to generate a resource including one or more of
chemicals, biomass, lipids, and biogas. The fermenting of an
organic feedstock with a rumen from a ruminant animal is herein
referred to as Managed Ecosystem Fermentation ("MEF") and is based
on naturally occurring colonies of microbes with thousands of
different species forming a symbiotic whole. A natural microbial
ecosystem is internally symbiotic, as the many species are
dependent upon each other and cannot be independently cultured. MEF
uses natural microbial ecosystems as a building block to develop
complex industrial processes. MEF installations use the metabolites
(otherwise referred to herein as "chemicals") and microbial mass
produced by the microbes, and the residuals from the feedstocks as
recovered products.
[0038] The conceptual differences between MEF and other natural or
industrial microbial processes is the degree of management control
applied and the number of products harvested. MEF is between the
two extremes of unmanaged microbial fermentations in anaerobic
digesters (AD) and the single species fermentations of the
pharmaceutical industry. MEF takes a role in actively managing and
controlling the microbial colony: adding species that produce
desired products, but avoids the DNA manipulations used in genetic
engineering. An example of a schematic diagram of an MEF is
illustrated in FIG. 2.
[0039] Management of many natural microbial species rather than
trying to add features to a single microbe has several major
advantages. The microbial species in a naturally occurring
microbial ecosystem already have their own niche in nature and many
cannot be cultured outside their ecosystem. These are not new
microbes, so they pose a low risk of becoming new pathogens.
Because all the species in a MEF function holistically, the need to
protect any one microbe or process from the "outside world" by
sterilizing all equipment and feedstock is a large cost that is
avoided. The diversity of microbes forms a self-defensive mechanism
to ensure survival of the microbial consortium. MEF processes can
screen potential mixtures of microbial ecosystems and their product
yields at a faster rate than scientists can modify the genetics of
a single species and test their results. MEF focuses on selecting
and combining many naturally occurring species into stable
ecosystems with additional properties beyond those of the original
ecosystem.
[0040] The characteristics of MEF offer several technical
advantages as an industrial process. For example, MEF occurs at
moderate temperatures and near atmospheric pressures, so
construction costs can be lower than processes with much higher
temperatures and pressures, such as pyrolysis.
[0041] Rumen produces few toxic materials, as evidenced by long
natural lifespans of many ruminants, indicating there should be
little risk of new toxins entering the environment from rumen based
MEF processes. Additionally, a strong QA/QC program will test and
verify product safety on an ongoing basis. In contrast, literature
points to the ability of rumen microbes to detoxify some
environmental toxins, including aflatoxin.
[0042] MEF is an anaerobic process operating near neutral pH
values, so the liability risk from a spill is limited. Oxygen in
the air will quickly halt the process and the fluid is only mildly
corrosive at pH 5 to 6.5. All of the microbes are naturally
occurring, many are soil bacteria, and unlikely to harm plants or
groundwater.
[0043] MEF is robust; ruminant animals can live 20 years without a
microbial failure. This robustness of MEF means lower maintenance
expenses in caring for the microbes.
[0044] MEF is adaptable to different feedstocks. The minimum
transition time from grass to grain for cattle is several days.
Microbes from cattle rumen also adapt to a wide variety of
feedstocks in the lab. This adaptability eliminates the need for
strain archiving as used in pharmaceuticals.
[0045] MEF can be modified by adding additional microbes to the
ecosystem. Research with Australian sheep has demonstrated that the
ability to digest specific tannins can be acquired by animals
receiving additional rumen microbes.
[0046] MEF does not require a sterilized feedstock. This property
avoids a process that could be very difficult and expensive for
high volume feedstocks.
[0047] The methods and compositions of the presently disclosed
subject matter are described in greater detail herein below.
DEFINITIONS
[0048] While the following terms are believed to be well understood
by one of ordinary skill in the art, the following definitions are
set forth to facilitate explanation of the presently disclosed
subject matter.
[0049] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning as commonly understood to one of
ordinary skill in the art to which the presently disclosed subject
matter belongs.
[0050] Following long-standing patent law convention, the terms
"a", "an", and "the" refer to "one or more" when used in this
application, including the claims. Thus, for example, reference to
"a chemical" or reference to "a lipid" includes a plurality of such
chemicals or such lipids, and so forth.
[0051] The term "metabolite" is herein used interchangeably, for
the purposes of the specification, drawings, and claims, with the
term "chemical".
[0052] As used herein, the blocks illustrated in FIGS. 2-12 are
sometimes referred to herein as "units" and are meant to represent
blocks of equipment that can contain multiple elements to perform
the various tasks.
[0053] As used herein, the term "feedstock" means the organic
materials placed into the MEF process for conversion to output
materials (or otherwise referred to herein as "resources"). The
term "organic feedstock" is used herein for the purposes of the
specification, drawings, and claims to refer to any feedstock of an
organic nature. The term "organic" as it is used herein for the
purposes of the specification, drawings, and claims, is meant to be
understood in its broadest sense as being of, relating to, or
derived from living matter. Accordingly, the organic feedstock of
the presently disclosed subject matter can comprise, for example,
but is not limited to one or more of catering waste, biodiesel
waste, agricultural waste, food processing plant waste, wood pulp,
shredded paper, paper mill sludge, cotton gin waste, sewage sludge,
slaughter house waste, organic fraction of municipal solid waste
(OFMSW), or algae, or combinations thereof. "Feed grade" organic
feedstock for the purposes of the specification, drawings, and
claims means organic material that is approved for feeding to
livestock. In some cases it may be abbreviated as ("FG") in this
document. "Adulterated" organic feedstock means for purposes of the
specification, drawings, and claims any organic material that is
not approved for feeding to livestock. Most organic wastes will be
considered adulterated and therefore the MEF products from these
sources will not be acceptable as animal feed.
[0054] The term "rumen" is used herein for the purposes of the
specification, drawings, and claims to refer to one or more of a
rumen from a ruminant animal. Specific examples of the rumen
include, for example, but are not limited to one or more of a
bovine rumen, a sheep rumen, a goat rumen, a deer rumen, or a bison
rumen, or combinations thereof. In addition to the rumen, one or
more microorganisms can be added to the MEF of the presently
disclosed subject matter. The term "microorganism" is herein used
interchangeably with the term "microbe" and means for the purposes
of the specification, drawings, and claims, any microscopic
organism. Examples of microorganisms include, but are not limited
to, bacteria, butyric acid producing bacteria including, for
example, Clostridium acetobutylicum, Clostridium butyricum,
Clostridium kluyveri, Clostridium pasteurianum, Fusobacterium
nucleatum, Butyrivibrio fibrisolvens, Eubacterium limosum,
cellulosic bacteria, earth worm microbes, termite microbes, cecum
microbes, rabbit cecum microbes, horse cecum microbes, yeast,
industrial yeast, brewer's yeast, fungi, Trichoderma reesei, and
protozoa, and combinations thereof. By "cellulosic bacteria" is
meant bacteria capable of breaking down cellulose, for example, by
hydrolysis. Cellulosic bacteria include bacteria in the rumen or
bacteria in the intestine of certain non-rumen species that are
capable of digesting cellulose to volatile fatty acids including
acetic, butyric, and propionic. By earth worm microbes or termite
microbes is meant the microbes in the gut of the earth worm or
termite that are capable of breaking down cellulose. By cecum
microbes is meant the microbes in the cecum of an animal that are
capable of breaking down cellulose. By Trichoderma reesei is meant
a fungus having the capacity to secrete large amounts of
cellulolytic enzymes such as, for example, cellulases and
hemicellulases.
[0055] The term "resource" is used herein for the purposes of the
specification, drawings, and claims to refer to one or more of
chemicals, lipids, volatile fatty acids ("VFAs"), long chain fatty
acids, acetic acid, proprionic acid, isobutyric acid, butyric acid,
isovaleric acid, valeric acid, lactic acid, hexanoic acid, ethanol,
butanol, biomass, high protein animal feed, fertilizer, phosphate
fertilizer, nitrogen fertilizer, proteins, amino acids, lysine,
enzymes, cellulase, alpha-amylase, histidase, lysozyme, penicillin
acylase, biogas, methane, hydrogen, carbon dioxide, and water.
[0056] The term "chemical" is meant to be interpreted in its
broadest sense for the purposes of the specification, drawings, and
claims, as anything made of matter that is present in the MEF of
the presently disclosed subject matter. In one sense, the term
"chemical" is used herein to mean any chemical, biochemical, or
metabolite that can be produced by a ruminant animal, produced by a
microorganism that is capable of breaking down cellulose, or
produced by a MEF. Specific examples of chemicals include, but are
not limited to, volatile fatty acids, long chain fatty acids,
acetic acid, proprionic acid, isobutyric acid, butyric acid,
isovaleric acid, valeric acid, lactic acid, hexanoic acid, ethanol,
and butanol.
[0057] The term "biomass" and the term "microbial biomass" and the
term "biomass product" and the term "biomass materials" are herein
used interchangeably, for the purposes of the specification,
drawings, and claims. "Biomass product" means for the purposes of
the specification, drawings, and claims, the output stream of the
MEF process containing the majority of the biomass in the form of
cells, cellular debris, proteins, enzymes, or amino acids. These
biomass materials can be removed from the system in the raw state
or processed further to make additional biomass products.
[0058] The term "protein" means, as it is used herein for the
purposes of the specification, drawings, and claims, any amino
acid, peptide, enzyme, or protein molecule and the term "protein"
is herein used interchangeably with the term "polypeptide" the term
"peptide" the term "amino acid" the term "enzyme" and a term for
any specific amino acid or any specific enzyme.
[0059] To assess how and what the MEF will produce, follow the flow
of carbon from feedstock to product. The carbon balance shown in
Table 1 has two parts because two stages of fermentation are used.
Stage one is the initial fermentation and modeled on the rumen
fermentation of cattle because that is the original source of the
microbial ecosystem. Stage two is a biogas generator consuming the
VFAs from stage one and is modeled on commercial biogas generators,
since it uses the same methanogenic microbes. The carbon balance
includes only the digestible fraction of the feedstock.
Indigestibles, such as lignin, are not part of the yield, but will
appear as compost material at the exit of the process. The
summarized values in Table 2 are the overall carbon allocations
across both processes.
TABLE-US-00001 TABLE 1 Carbon Partitioning Carbon Partitions in
each stage of fermentation occurring in MEF. Stage 1 Process: Stage
1 Stage 2 Process: Stage 2 Composite Carbon Partition Total
Acidogenesis Percent Methanogenesis Percent Stage 1 + 2 = Total
Percent Chemicals; VFA 56.0% VFA .fwdarw. CH.sub.4 60.0% Chemical,
VFA .fwdarw. CH.sub.4 33.6% VFA .fwdarw. CO.sub.2 40.0% Chemical,
VFA .fwdarw. CO.sub.2 22.4% Biomass; Microbes 25.0% Biomass;
Microbes 25.0% Fermentation gas (CO.sub.2) 18.5% Fermentation gas
(CO.sub.2) 18.5% Fermentation gas (CH.sub.4) 0.5% Fermentation gas
(CH.sub.4) 0.5% Totals: 100.0% Totals: 100.0% Totals: 100.0%
TABLE-US-00002 TABLE 2 Digested Carbon Summary Summary of carbon
partition Carbon Allocation Percent Methane 34% Carbon Dioxide 41%
Microbial Carbon 25% Total: 100%
[0060] The yields of methane and biomass are the sources of income,
with biomass having far more value than methane. In one embodiment,
the methane is converted to electric power and process heat as part
of the process. The yield of methane appears adequate to provide
enough heat and power to drive the overall process.
[0061] The biomass is a composite of cells, enzymes, proteins, and
amino acids. While this material can be harvested dried and used in
bulk as fertilizer or a high protein animal feed (HPAF), there is
significant potential income in separating enzymes and amino acids
for sale separately. MEF as an industrial process is more complex
than a biogas unit, but the HPAF and other bio-products sell for
much more than the methane or electricity.
[0062] Managed Ecosystem Fermentation (MEF) systems, processes, and
methods for implementing thereof are disclosed herein (see FIGS.
2-12). The MEF has several important characteristics. The microbial
fermentations exist symbiotically within a controlled mechanical
environment. The microbial ecosystem is symbiotic between the many
species within the fermentation and also the entire ecosystem is
symbiotically dependent on the external mechanical environment in
which it is located. Manipulation of the external environment is
one of the management tools used in MEF processes.
[0063] The Managed Ecosystem Fermentation (MEF) system of the
presently disclosed subject matter does not require sterilized
feedstocks. The diversity of species within the ecosystem appear to
offer protection to the entire ecosystem. No animal sterilizes
everything it eats; the digestive microbial ecosystem appears to
protect it. The MEF processes described herein utilize the
diversity of microbial species as a protective mechanism, so
sterilization of the feedstock is not required.
[0064] Ecosystem fermentations can consume a wide variety of
organic materials, and provide a stable output for years at a time.
The behavior of rumen in cattle fed on pasture or fed on grain is
different; however, a transition time is required between the two
feeding programs. The human diet demonstrates this diversity of
inputs and long term stability. Controlling of the feedstock input
characteristics can manipulate the output materials from the MEF
system, providing another management tool used in MEF
processes.
[0065] MEF processes can be adapted to new tasks by manipulating
which microbial species are present in the ecosystem. Hybridizing
the microbial ecosystem by controlling which specific species are
included in the managed ecosystem is another tool for operating MEF
installations.
[0066] Ecosystem processes can produce a wide variety of chemicals
and biomass species simultaneously. MEF processes can extract the
chemicals and biomass produced; together or separately, as solids,
liquids or gases. The chemicals and biomass materials can be
further separated into chemical families or individual
compounds.
[0067] In one embodiment, the presently disclosed subject matter
provides a method for generating resources from feedstocks, the
method comprising fermenting an organic feedstock with a rumen to
generate a resource.
[0068] For the MEF methods and systems of the presently disclosed
subject matter, the organic feedstock can include, for example, but
is not limited to catering waste, biodiesel waste, agricultural
waste, food processing plant waste, wood pulp, shredded paper,
paper mill sludge, cotton gin waste, sewage sludge, slaughter house
waste, organic fraction of municipal solid waste (OFMSW), or algae,
or combinations thereof.
[0069] For the MEF methods and systems of the presently disclosed
subject matter, the rumen is one or more of a rumen from a ruminant
animal, and specific examples include, but are not limited to a
bovine rumen, a sheep rumen, a goat rumen, a deer rumen, or a bison
rumen, or combinations thereof.
[0070] The resources generated in the MEF methods and systems of
the presently disclosed subject matter are one or more of
chemicals, lipids, volatile fatty acids, long chain fatty acids,
acetic acid, proprionic acid, isobutyric acid, butyric acid,
isovaleric acid, valeric acid, lactic acid, hexanoic acid, biomass,
high protein animal feed, fertilizer, phosphate fertilizer,
nitrogen fertilizer, proteins, amino acids, lysine, enzymes,
cellulase, alpha-amylase, histidase, lysozyme, penicillin acylase,
ethanol, butanol, biogas, methane, hydrogen, carbon dioxide, and
water.
[0071] One embodiment of the method is depicted in the flow diagram
illustrated in FIG. 2. FIG. 2 shows a Managed Ecosystem
Fermentation (MEF) train for generating resources including
chemical products, biomass products, and reclaimed water from
fermentation of the organic feedstock with the rumen. In this
embodiment, the method comprises stirring and/or agitating the
organic feedstock during the fermenting and separating the
chemicals in the fermentation liquid from the particulate biomass
using one or more filters, or other separation technologies, which
is depicted in FIG. 2 as "Particulate Separation."
[0072] Another embodiment is depicted in the flow diagram
illustrated in FIG. 3. FIG. 3 shows a Managed Ecosystem
Fermentation (MEF) train for generating resources including
chemicals, lipids, biomass, biogas, power and heat, and reclaimed
water from fermentation of the organic feedstock with the rumen. In
this embodiment, the method comprises fractionating each of the
lipids, chemicals, biomass, and biogas from the fermenter based on
the physical properties of each resource. For example, the lipids
float to the top of the fermentation liquid, the chemicals are
soluble in the fermentation liquid, a significant portion of the
biomass sinks to the bottom of the fermenter, and the biogas is in
the gas phase. As illustrated in FIG. 3, the lipids are
fractionated from the top section of the fermenter, the biomass is
fractionated from the bottom section of the fermenter, the
chemicals are fractionated from the middle section of the
fermenter, and the gas is released from the top of the
fermenter.
[0073] In one embodiment of the method of fermenting an organic
feedstock with a rumen to generate a resource, the method comprises
recycling the organic feedstock that is undigested through a
grinder/mixer. This embodiment is illustrated in FIGS. 2 and 3.
[0074] In one embodiment of the method of fermenting an organic
feedstock with a rumen to generate a resource, the method comprises
re-inoculating the organic feedstock with the rumen. In one
embodiment, the re-inoculating is periodic. The re-inoculating is
performed using the rumen and microbe addition port illustrated in
FIGS. 2 and 3.
[0075] In one embodiment of the method of fermenting an organic
feedstock with a rumen to generate a resource, the method comprises
removing a portion of the chemicals that are acidic to maintain the
fermenting at a pH in a range between about pH 4 to about pH 9. In
one embodiment, the pH range is between about pH 5 to about pH 8.
In one embodiment, removing the acidic chemicals is continuous. In
one embodiment, the acidic chemicals comprise VFAs.
[0076] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the method comprises
employing a process to generate power and/or heat for the method,
wherein the process utilizes at least a portion of the resource
chemicals, the resource hydrogen, and/or the resource biogas.
[0077] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the method comprises
reclaiming at least a portion of the generated resource water.
[0078] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the method comprises
adding one or more of a microorganism, bacteria, butyric acid
producing bacteria, cellulosic bacteria, Clostridium
acetobutylicium bacteria, yeast, industrial yeast, brewer's yeast,
Trichoderma reesei, fungi, protozoa, earth worm microbes, termite
microbes, cecum microbes, rabbit cecum microbes, or horse cecum
microbes, or combinations thereof.
[0079] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the method comprises
separating one or more of the chemicals in a chemical separation
unit. This embodiment is illustrated in FIGS. 2 and 3. In one
embodiment, the chemicals comprise one or more of volatile fatty
acids, long chain fatty acids, acetic acid, proprionic acid,
isobutyric acid, butyric acid, isovaleric acid, valeric acid,
lactic acid, or hexanoic acid, and the chemical separation unit
comprises an ion exchange technology to effectuate separation of
one or more of the chemicals.
[0080] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the method comprises
separating the lipids from the biomass, the feedstock, and the
water. This embodiment is illustrated in FIG. 3.
[0081] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, one of the resources
generated is chemicals, and the method comprises shunting at least
a portion of the chemicals to a biogas generator, wherein the
biogas generator is a second fermenter that comprises the rumen;
and fermenting the chemicals and the rumen in the biogas generator
to generate biogas. This embodiment is illustrated in FIG. 3. In
one embodiment, the method comprises separating one or more of the
chemicals in a chemical separation unit, wherein the separated
chemicals comprise acetic acid, and shunting the separated acetic
acid to the biogas generator. In one embodiment, the fermenting in
the biogas generator is performed at a pH of above about pH 6.2 to
select for generation of the resource biogas. In one embodiment,
the method comprises employing the generated biogas from the biogas
generator to power the method.
[0082] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, one of the resources
generated is chemicals and the comprises separating one or more of
the chemicals in a chemical separation unit, wherein the separated
chemicals comprise acetic acid; and shunting at least a portion of
the separated chemicals comprising acetic acid to a ceramic oxide
fuel cell process for generating power from the acetic acid; and
utilizing the generated power in the method. This embodiment is
illustrated in FIG. 3.
[0083] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the resource
comprises biomass and the method comprises fractionating and/or
separating the resource biomass using particulate separation and
dewatering the biomass. This embodiment is illustrated in FIGS. 2
and 3. In one embodiment of the method, the organic feedstock is an
adulterated feedstock and the dewatered biomass is a soil enhancer
having live microbes. This embodiment is depicted in FIG. 4. In one
embodiment, the method comprises utilizing at least a portion of
one or more of the resources comprising chemicals, hydrogen, or
biogas to generate power for the dewatering. In one embodiment, the
method comprises drying the dewatered biomass. In one embodiment,
the organic feedstock is a feed grade feedstock and the dewatered
and dried biomass is a high protein animal feed (HPAF). This
embodiment is depicted in FIG. 5. In one embodiment, the organic
feedstock is an adulterated feedstock and the dewatered and dried
biomass is a dry fertilizer. This embodiment is depicted in FIG. 6.
In one embodiment, the method comprises utilizing at least a
portion of one or more of the resource chemicals, resource
hydrogen, or resource biogas that are generated to generate power
and/or heat for the dewatering and drying.
[0084] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the method comprises
applying a process for growing algae with the carbon dioxide
produced by the method.
[0085] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the fermenting is
not performed under sterile conditions.
[0086] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the method comprises
adding one or more substances capable of being utilized as a source
of nitrogen in the fermenting. In one embodiment, the substance is
selected from the group consisting of ammonia, urea, amino acids,
and amines, and combinations thereof.
[0087] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the feedstock
comprises catering waste and the rumen comprises bovine rumen.
[0088] In one embodiment, the feedstock comprises catering waste
and the rumen comprises bovine rumen and the method comprises
adding ammonia. In one embodiment, the feedstock comprises catering
waste, the rumen comprises bovine rumen, and the feedstock further
comprises biodiesel waste. In one embodiment, the rumen further
comprises sheep rumen. In one embodiment, the feedstock comprises
catering waste, the rumen comprises bovine rumen, and the method
comprises adding a butyric acid producing bacteria. In one
embodiment, the butyric acid producing bacteria is Clostridium
acetobutylicum bacteria.
[0089] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the resource
comprises lipids, chemicals, biogas, and biomass, and the method
comprises fractionating and/or separating through particulate
separation the resource lipids, chemicals, biogas, and biomass; and
producing one or more of a chemical product, a lipid product, a
biogas, a biomass product, a fertilizer, a high protein animal
feed, a soil enhancer with live microbes, acetic acid, proprionic
acid, isobutyric acid, butyric acid, isovaleric acid, valeric acid,
lactic acid, or hexanoic acid, or combinations thereof. In one
embodiment, the organic feedstock comprises algae and the lipid
product is produced.
[0090] In one embodiment of the method for fermenting an organic
feedstock with a rumen to generate a resource, the method comprises
monitoring and/or controlling the fermenting from a remote
facility, wherein the monitoring and/or controlling is effectuated
through use of a communications link between the fermenting and the
remote facility. In one embodiment of the method, the
communications link comprises a cabled or wireless technology.
[0091] In one embodiment, the presently disclosed subject matter
provides a resource generated according to the method provided
herein, the method comprising fermenting an organic feedstock with
a rumen to generate the resource. The resource provided is selected
from the group consisting of chemicals, lipids, volatile fatty
acids, long chain fatty acids, acetic acid, proprionic acid,
isobutyric acid, butyric acid, isovaleric acid, valeric acid,
lactic acid, hexanoic acid, biomass, high protein animal feed,
fertilizer, phosphate fertilizer, nitrogen fertilizer, proteins,
amino acids, lysine, enzymes, cellulase, alpha-amylase, histidase,
lysozyme, penicillin acylase, ethanol, butanol, biogas, methane,
hydrogen, carbon dioxide, and water, and combinations thereof.
[0092] In one embodiment, the presently disclosed subject matter
provides a system comprising a grinder/mixer configured to receive
the organic feedstock and the rumen, and a fermenter configured to
receive the organic feedstock and the rumen, and the fermenter
configured to ferment the organic feedstock to generate a resource.
This embodiment is illustrated in FIGS. 2-7 and 9-11. In one
embodiment of the system, the fermenter is configured to recycle
the organic feedstock that is undigested through the grinder/mixer.
In one embodiment of the system, the grinder/mixer is configured
for re-inoculation of the organic feedstock with the rumen. In one
embodiment of the system, the re-inoculation is periodic.
[0093] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the system
comprises a power generator configured to utilize at least a
portion of the resource chemicals, the resource hydrogen, and/or
the resource biogas to generate power and/or heat for the system.
In one embodiment, the system comprises a water reclamation
unit.
[0094] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the
fermenter is configured to stir and/or agitate the organic
feedstock and rumen during the fermentation. In one embodiment, the
resource comprises chemicals and biomass, and the system comprises
a particulate separation unit configured to separate the chemicals
from the biomass. This embodiment is illustrated in FIG. 2.
[0095] In one embodiment of the system for generating resources
from feedstocks, the fermenter is configured to fractionate one or
more of the resources selected from the group consisting of lipids,
chemicals, biogas, and biomass. This embodiment is illustrated in
FIG. 3.
[0096] In one embodiment of the system for generating resources
from feedstocks, the resource comprises chemicals and the fermenter
is configured for removal of a portion of the chemicals that are
acidic to maintain the pH of the fermentation in a range between
about pH 4 to about pH 9. In one embodiment, the pH of the
fermentation is maintained in a range between about pH 5 to about
pH 8. In one embodiment, the fermenter is configured for the
removal of the chemicals in a continuous manner. In one embodiment,
the acidic chemicals that are removed comprise VFAs.
[0097] In one embodiment of the system for generating resources
from feedstocks, the grinder/mixer is configured to receive one or
more of a microorganism, a bacteria, a butyric acid producing
bacteria, a cellulosic bacteria, a Clostridium acetobutylicium
bacteria, a yeast, an industrial yeast, a brewer's yeast, a
Trichoderma reesei, a fungi, a protozoa, earth worm microbes,
termite microbes, cecum microbes, rabbit cecum microbes, or horse
cecum microbes, or combinations thereof.
[0098] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the system
comprises a chemical separation unit configured to separate one or
more of the chemicals. In one embodiment of the system, the
chemicals comprise one or more of volatile fatty acids, long chain
fatty acids, acetic acid, proprionic acid, isobutyric acid, butyric
acid, isovaleric acid, valeric acid, lactic acid, or hexanoic acid,
and the chemical separation unit comprises an ion exchange
technology. In one embodiment, the system comprises a lipid
separation unit configured to separate the lipids from the biomass,
the feedstock, and the water.
[0099] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the
resource generated comprises chemicals, and the system comprises a
biogas generator configured as a second fermenter to receive the
rumen and at least a portion of the chemicals to generate biogas.
In one embodiment of the system, the chemicals comprise acetic acid
and the system comprises a chemical separation unit configured to
separate at least a portion of the acetic acid, wherein the
separated acetic acid is shunted to the biogas generator. In one
embodiment of the system, the biogas generator is maintained at a
pH of above about pH 6.2. In one embodiment of the system, the
generated biogas is employed to power the system.
[0100] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the
resource generated comprises chemicals and the system comprises a
chemical separation unit configured to separate one or more of the
chemicals, wherein the separated chemicals comprise acetic acid,
and a ceramic oxide fuel cell unit configured to receive and to
generate power from the separated acetic acid, wherein the
generated power is utilized in the system.
[0101] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the system
comprises a particulate separation unit configured to separate the
biomass or the fermenter is configured to fractionate the biomass;
the system comprises a biomass separation unit; and the system
comprises a biomass dewatering unit configured to dewater the
biomass. In one embodiment of the system, the organic feedstock is
an adulterated feedstock and the dewatered biomass is a soil
enhancer having live microbes. This embodiment of the system is
depicted in FIG. 4. In one embodiment of the system, the system
comprises a power generator configured to utilize at least a
portion of one or more of the generated resources comprising
chemicals, hydrogen, or biogas to generate power for the
dewatering. In one embodiment, the system comprises a biomass
drying unit configured to dry the dewatered biomass. In one
embodiment of the system, the organic feedstock is a feed grade
feedstock and the dewatered and dried biomass is a high protein
animal feed (HPAF). This embodiment of the system is depicted in
FIG. 5. In one embodiment of the system, the organic feedstock is
an adulterated feedstock and the dewatered and dried biomass is a
dry fertilizer. This embodiment of the system is depicted in FIG.
6. In one embodiment, the system comprises a power generator
configured to utilize at least a portion of one or more of the
generated resources comprising chemicals, hydrogen, or biogas to
generate power for the dewatering and/or drying.
[0102] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the system
comprises an algal growth unit configured for growing algae with
the generated resource carbon dioxide.
[0103] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the system
is not configured to be operated under sterile conditions.
[0104] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the
grinder/mixer is configured to receive to receive one or more
substances capable of being utilized as a source of nitrogen in the
fermenting. In one embodiment of the system, the substance is
selected from the group consisting of ammonia, urea, amino acids,
or amines, or combinations thereof.
[0105] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the
organic feedstock comprises catering waste and the rumen comprises
bovine rumen. In one embodiment of the system, the organic
feedstock comprises catering waste, the rumen comprises bovine
rumen, and the mixer/grinder is configured to receive addition of
ammonia. In one embodiment of the system, the organic feedstock
comprises catering waste, the rumen comprises bovine rumen, and the
organic feedstock comprises biodiesel waste. In one embodiment of
the system, the organic feedstock comprises catering waste and the
rumen comprises a mixture of bovine rumen and sheep rumen. In one
embodiment of the system, the organic feedstock comprises catering
waste, the rumen comprises bovine rumen, and the mixer/grinder is
configured to receive addition of a butyric acid producing
bacteria. In one embodiment of the system, the butyric acid
producing bacteria is Clostridium acetobutylicium bacteria.
[0106] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the
resource comprises chemicals, biomass, lipids, and biogas, and the
system comprises the fermenter configured to fractionate the
resource chemicals, biomass, lipids, and biogas; a chemical
separation unit configured to generate a chemical product; and a
biomass separation unit configured to generate a biomass product.
This embodiment is illustrated in FIG. 3. In one embodiment of the
system, the system comprises a biogas generator configured to
generate biogas from at least a portion of the chemicals. In one
embodiment of the system, the system comprises a lipid separation
unit configured to generate a lipid product. In one embodiment of
the system, the feedstock comprises algae and the lipid product is
the lipid from the algae. In one embodiment of the system, the
chemical product comprises an acetic acid, a proprionic acid, an
isobutyric acid, a butyric acid, an isovaleric acid, a valeric
acid, a lactic acid, or a hexanoic acid, or combinations thereof.
In one embodiment of the system, the biomass product is selected
from the group consisting of a fertilizer, a high protein animal
feed, and a soil enhancer having live microbes. This embodiment is
illustrated in FIGS. 4-6. In one embodiment, the system comprises a
power generation and heat recovery unit configured to generate
power and/or heat, wherein the generated power and/or heat are
utilized in the system.
[0107] In one embodiment of the system configured to ferment the
organic feedstock with the rumen to generate a resource, the system
comprises a remote facility configured to monitor and/or control
the fermenter through use of a communications link between the
remote facility and the fermenter. In one embodiment of the system,
the communications link is configured as a cabled or a wireless
technology.
[0108] One embodiment of the presently disclosed subject matter is
a process for preparing and biologically converting organic waste
and/or other organic materials into chemicals, biomass and residual
materials, then recovering multiple products, plus reclaimed water.
The general process is shown in FIG. 7.
[0109] The biological process uses an ecosystem approach employing
dozens to thousands of species of microorganisms that provides
greater flexibility to handle heterogeneous waste streams (i.e.,
waste streams of more than a single type of waste) than traditional
fermentation systems and higher levels of specificity of product
output than anaerobic digestion systems. This process is called
Managed Ecosystem Fermentation (MEF). In one embodiment, the
chemicals and biomass materials are recovered from the process and
separated by particle size into multiple streams for
processing.
[0110] One embodiment of the disclosed subject matter is the
process for control and management of the feedstock materials to
maintain desired properties within the MEF, the chemicals, the
biomass or the residuals. An example of this embodiment would be
the blending of two or more feedstock materials (or additive
materials); such as sewage sludge and yard waste or municipal solid
waste; to obtain the desired carbon-to-nitrogen ratio, pH or other
properties of the blend that could improve fermentation
efficiency.
[0111] One embodiment of the disclosed subject matter is the
process for the extraction of chemicals from the MEF process fluids
to maintain pH conditions within the MEF vessel or to extract
specific materials from the chemicals. Most of the liquid chemicals
from MEF will be volatile fatty acids; as acetate, propionate and
butyrate. The chemicals also contain small fractions of longer
chain fatty acids and carboxylic acids. In one embodiment, the
chemicals are separated in a chemical separation unit. In one
embodiment, chemical separation is effectuated using ion exchange
technology. The ion exchange technology can include, for example,
the use of an anion exchange matrix known to those of skill in the
art to bind and recover carboxylic acids such as, for example, the
VFAs in the fermentation broth. In one example the anion exchange
matrix is a fluidized bed anion exchange matrix. In one embodiment,
the first step is to remove some fraction of the fermentation broth
from the MEF vessel and filter the removed broth by size exclusion
to remove feedstock materials and most biomass materials from the
remaining liquid fraction; such that the remaining liquid consists
or comprises mostly the chemicals, buffers, and water. In one
embodiment, the second step is the removal of the chemicals from
the water and buffer solution, such that the buffers are restored
and pH of the solution is raised to the desired value for
recirculation back into the fermentation.
[0112] In one embodiment, at least a portion of the removed
chemicals are shunted to an additional microbial fermentation tank
configured as a biogas generator to convert the VFAs in the
filtered liquid solution into methane and carbon dioxide using
methanogenic microbes. This embodiment is illustrated for example
in FIGS. 3-6 and 9-11. These methanogenic microbes convert acetate
and other volatile fatty acids in the mixed liquid solution into a
methane and carbon dioxide, gas phase materials that may be easily
separated by gravity from the remaining liquids. In one embodiment,
the methanogenic bacteria are present in the rumen and the
generation of biogas is selected for in the biogas generator by
maintaining the pH in the biogas generator above about pH 6.2.
Other processes for removing the chemicals from the filtered
fermentation broth can be employed in this embodiment of
controlling the MEF process.
[0113] One aspect of the presently disclosed subject matter is the
process method for separating specific protein species from the
fermentation broth using a series of specialized filter materials,
each prepared to capture only one protein (or enzyme or amino
acid). These filter materials can have the substrate form of
textiles, membranes, beads, or other solid material. This substrate
material is treated to form many ligand sites that will anchor one
of many specific "capture" compounds, each of which can bind one of
the molecules of interest from the fermentation broth. The
substrate, ligand and capture chemical together form a filtering
material which allows the fermentation fluid to intimately contact
the capture compound sites, for the purpose of binding the target
protein material and effecting its removal from the fermentation
fluid.
[0114] In one embodiment of the presently disclosed subject matter,
functionalized filters are utilized in a series flow arrangement to
capture one or more proteins from the MEF (see, e.g. US Patent
Publication No. 2007/0161308). In this embodiment, many filters are
arranged in a series flow arrangement, where each filter or set of
filters is functionalized to bind a different protein (FIG. 12).
The purpose of this arrangement is to extract different protein
species from a common fermentation fluid, such that each protein
species is captured on a separate filter or set of filters.
[0115] This embodiment is different from U.S. Pat. No. 7,285,219
titled "Chromatographic separation member and method," in that the
substrate is not a solid film, but may be beads or a textile felt
with much greater surface area. While this embodiment can use the
principle of repeatedly removing single protein species from a
fluid mixture with a material assembly that can bind the protein of
interest or using displacement chromatography, both apparently used
in U.S. Pat. No. 7,285,219, the substrate need not be a polymer
film, as required in said patent. Another difference in this
embodiment and said patent is that the binding chemical and release
agents can utilize a different chemical principle, other than
chromatography.
[0116] One embodiment of the presently disclosed subject matter is
the process method for custom blending of additional species of
naturally occurring microbes into an existing ecosystem of natural
microbes that is already living symbiotically inside a mechanically
maintained environment. The blending microbes can be another
microbial ecosystem, multiple ecosystems, single species of microbe
or small set of microbial species. The purpose of this microbial
blending is to enhance specific properties of the managed ecosystem
fermentation process. These additional properties can be for
consumption of specific compounds in the feedstock material, or
production of specific chemicals, or production of specific biomass
proteins, or preservation of specific compounds from the feedstock
within the fermentation fluid. In one embodiment, the microbial
blending can be by adding to the fermentation one or more of a
microorganism such as, for example, a bacteria, a butyric acid
producing bacteria, a cellulosic bacteria, a Clostridium
acetobutylicium bacteria, a yeast, an industrial yeast, a brewer's
yeast, a Trichoderma reesei, a fungi, a protozoa, earth worm
microbes, termite microbes, cecum microbes, rabbit cecum microbes,
or horse cecum microbes.
[0117] One embodiment of the presently disclosed subject matter is
the ability to distribute many MEF systems in a region and control
them from a central location. This aspect is one feature of a
manufacturing system architecture called Distributed, Integrated
Biochemical Manufacturing (DIBM). The MEF process equipment (the
Remote Conversion Unit, RCU) is located at the point of feedstock
concentration such that transportation expense of raw materials is
reduced. Each RCU is connected to a Central Facility (CF) by a
communications link that can include any cabled or wireless
technology with adequate bandwidth and range. The central control
room has direct monitoring and control over each RCU within its
assigned region. Personnel in the central control room will
dispatch workers to the RCUs for normal operations, maintenance and
emergency tasks. This architecture centralizes the monitoring tasks
because MEF processes usually change slowly, but any chemical or
biological process does need a minimum level of monitoring at all
times.
[0118] Control can be passed to more remote control rooms in other
regions or a central office as desired, creating the opportunity
for redundant monitoring and control capabilities, as a safety
system.
[0119] Labor assignments can be optimized to minimize response time
or miles driven. Sharing both skilled operators and maintenance
personnel between a large number of sites can increase labor
utilization rates and apply high skill levels when and where
needed.
[0120] Material collection routes for routine operations can be
established to minimize miles driven per ton of material
collected.
[0121] One embodiment of the presently disclosed subject matter is
the ability of the Central Facilities to integrate the output
materials from many RCUs, which may be utilizing different sources
of adulterated feedstocks. This embodiment does not implement any
mixing of adulterated materials into any feed grade materials.
Separating the adulterated and feed grade material classes is
necessary for animal safety and regulatory compliance. This aspect
is a feature of the DIBM manufacturing system architecture. Because
MEF processes produce common chemicals, some common proteins, and
other fungible products, the DIBM system architecture can aggregate
the fungible materials at the CF for further processing. The
advantage of DIBM is the economies of scale it provides in
manufacturing secondary products from the RCU products, while
minimizing transport cost of raw materials for initial
conversion.
[0122] Not all materials must flow from the RCU to the CF. Where
the products of particular RCUs are not fungible, such as animal
feed or other feed grade production, these products may be
delivered directly to local customers, such as sending the animal
feed product directly to a feed mill.
[0123] One embodiment of the presently disclosed subject matter is
the product of a low moisture High Protein Animal Feed (HPAF) that
can be used in the diets of farm animals. This material is fed to
animals, so the feedstock must be feed grade materials. The MEF
produces the protein for this material from the carbohydrates,
often including cellulose, found in the feedstock material. The
physical and nutritional properties can be adjusted for blending
into the dry diet of the animal populations. It is expected that
the HPAF will have a protein concentration between 10% and 50%
depending on local conditions and customer preference. It is
expected that the physical format of HPAF will be dried pellets,
similar to dog kibble, to reduce dusting during shipment and
improve blending properties for the feed mill. Other form factors
for this material can be considered.
[0124] One embodiment of the presently disclosed subject matter is
the product of an animal feed flavoring agent that is added to feed
mixtures to improve the palatability of other materials. This
material is fed to animals, so the feedstock must be feed grade
materials. The MEF process produces the biomass for this material
from the carbohydrates, often including cellulose, found in the
feedstock material. This material is the concentrated biomass
extract from the fermentation, containing a high density of the
microbes and enough liquids to remain easily handled. Chemical
liquids may be included in this material. The material is heated
and/or oxygenated adequately to kill the microbes and ensure
product safety.
[0125] One embodiment of the presently disclosed subject matter is
the product of a low moisture pelletized fertilizer product that
provides an organic source of nitrogen and phosphorous. This
material is not intended to be used as animal feed or to be applied
to growing crops, so it may be manufactured from adulterated
organic materials. The MEF process produces the biomass for this
material from the carbohydrates, often including cellulose, found
in the feedstock material. The biomass is dried and thermally
denatured so that the protein in the biomass will become
bio-available nitrogen, phosphorus and organic matter for plants.
The physical properties and packaging of this material can be
adjusted to suit local markets.
[0126] One embodiment of the presently disclosed subject matter is
the product of living anaerobic microbes that can be incorporated
into soils to enhance and reinforce the endogenous microbial
populations. The purpose for this material is to improve plant
yields by enhancing microbial activity in the soil. The form of
this material is an anaerobic liquid slurry that is incorporated
into the soil below the surface to limit oxygen exposure during
application.
[0127] One embodiment of the presently disclosed subject matter is
the detoxification of specific organic agents. For example, cattle
have demonstrated that rumen is able to detoxify certain organic
compounds, including aflatoxin. In another example, research with
Australian sheep has demonstrated that the ability to digest
specific tannins can be acquired by animals receiving additional
rumen microbes. Another example is research showing that
Escherichia coli are displaced in rumen and only found in very
small numbers in rumen. Accordingly, in one embodiment, the MEF
process can be utilized as a disposal method for organic agents
that will be tested and identified.
[0128] In one embodiment, a method is provided for a detoxification
service where the customer brings the material to an operating MEF
site that has demonstrated the capability to denature or destroy
the chemical and/or organic agent in question. In another
embodiment, a method is provided for a specific set of microbe
species to be installed in a non-MEF ecosystem fermentation, such
as a wastewater treatment plant for the purpose of adding the
microbial capacity to denature or consume specific organic targets
that were not sufficiently treated by the original ecosystem.
Target agents for consumption include estrogens in wastewater and
pharmaceutical compounds in wastewater. Microbial sets for this
embodiment are developed using the technology described herein.
[0129] The equipment described in this section is shown in FIG. 7,
which illustrates a general process diagram for an MEF train
according to the presently disclosed subject matter. These "Units"
are blocks of equipment that may contain multiple elements to
perform the tasks.
[0130] Unit 1, Grinder Mixer.
[0131] This equipment performs three tasks before sending the
slurry to the fermenter: 1) reduce the feedstock to a range of
sizes appropriate for the fermentation; 2) introduce the
recirculated buffer solution and the inoculating microbes to the
feedstock; and 3) provide proper mixing and water dilution between
the feedstock and recirculation fluids.
[0132] The initial size reduction to a top size of about 5 cm is a
coarse grind and approximates the initial mastication of cattle
during grazing. The large top size during the first pass will
minimize the energy required for size reduction. As materials are
recycled back to the grinder-mixer from the cascade filter, their
size will be further reduced by passing through the grinder again.
The energy requirement for the second and subsequent passes will be
lower as a result of the initial enzyme attack on the fibers. This
equipment will have a water jacket as necessary to bring the slurry
to the operating temperature of the fermenter.
[0133] The feedstock mixing with buffer, water and microbes will
form a slurry with the proper solids content, pH and inoculation to
initiate fermentation of the feedstock. The final step within the
grinder mixer unit is to pump the slurry into the fermenter with
sufficient velocity to rapidly mix the slurry into the fermentation
broth.
[0134] Unit 2, Fermenter.
[0135] This equipment provides the residence time and controlled
conditions for the microbial ecosystem within the Unit to digest
the feedstock materials into chemicals, biomass and residual
materials.
[0136] The controlled environmental factors within this unit may
include residence time, agitation shear rate, temperature, fluid
pH, redox potential, headspace atmospheric composition and
pressure. Each of these values can be measured in the fermenter or
nearby piping and connected to a central monitoring and control
network. The specific value of each control point will depend on
the feedstock, the constituent makeup of the microbial ecosystem,
and the product mix desired at the outputs. The ability to
influence the output chemistry by manipulating the inputs and
control points is an important feature of MEF that demonstrates the
flexibility of the processes.
[0137] System residence is calculated on the time elapsed in the
grinder-mixer, fermenter, and cascade filter units and associated
piping. The residence time within the system is different for
liquids and solids. Liquid residence time is based on the rate of
chemical production and buffer content because the pH of the broth
has to remain in control, typically a value between 5.5 and 7.0. As
fermentation rates increase, the liquid residence time will
decrease, which increases the chemical removal rate to maintain the
pH setpoint.
[0138] The residence time for the solids in the system will depend
on particle size and other factors, such as the solids blowdown
rate, used for removal of indigestible materials. In most
ruminants, the solids residence time is between 1 and 3 days,
depending on the animal species and their diet. Solids residence
time for MEF processes is expected to be similar to the rumen
process because similar microbes are the driving force for solids
reduction in both cases.
[0139] Unit 3, Cascade Filter.
[0140] This unit consists or comprises of a set of membranes,
arranged in order of descending pore size, as shown in FIG. 8. Each
membrane of the cascade is in a cross-flow geometry, with adequate
retentate flow to minimize the cake buildup on the membrane. The
total number of membranes will depend on the caking characteristics
of the fermentation and is expected to vary with different
feedstocks and microbial ecosystems. The expected minimum screen
set would include retaining the larger pieces of digesta for return
to the fermentation system. There may be several screens in this
set, depending on the particle size distribution and caking
characteristics of the fermentation materials. These physical
properties of the fluid will determine the number of screens, the
pore sizes required and the necessary tangential flow rates for
proper operation. These values will be determined empirically for
each major type of feedstock encountered but the minimum pore size
is expected to be approximately 5 microns. All of the flow retained
on the screens of the first stage will be recirculated back to the
Unit 1 Grinder-Mixer.
[0141] The second set of screens is an important design element of
the MEF train as it allows the initial separation between the
biomass and the chemicals extracted from the fermentation, so that
each of these materials can be processed independently for greater
total revenue. This pore size is below the larger particles of
incompletely digested feedstock and larger than the molecular size
of the chemical chemicals, so that most of the solids from the
biomass materials are retained on the membrane.
[0142] The task of the second set of screens is to capture the
particulate material that passes the first set of screens and is
retained on the second, where the second screen set may have a
minimum size of 0.2 microns, in order to retain cells, cell debris,
proteins, enzymes and amino acids from the fermentation. The
material retained on these screens, including enough fluid to
transport this material easily, is conveyed to Unit #4, the biomass
separation unit.
[0143] The material passing the second set of screens is the water,
buffering salts and the chemical chemicals as volatile fatty acids
(VFAs) and longer chain carboxylic acids (C.sub.5 to C.sub.21),
from the fermentation fluid. These materials are sent to Unit #5
for chemical processing into output products.
[0144] Unit 4, Biomass Separation.
[0145] This unit receives flow of mixed biomass from the Unit 3
Cascade Filter. This unit will process the mixed biomass into
output products that can be transported from the site. Several
different technologies can be incorporated into this unit,
depending on the feedstock available and products desired.
[0146] Because the technology of this unit depends on the feedstock
and products selected, the equipment details of this unit are
listed in each of the examples below.
[0147] Unit 5, Chemical Separation.
[0148] This unit receives flow from Unit 3 that has passed a
micro-filtration level, so that there are few particulates, such as
microbial biomass, within this stream. The major components of this
stream are water, dissolved buffer salts, VFAs, and longer chain
carboxylic acids that are the dominant chemical compounds produced
by most microbial ecosystems described herein. This unit will
reduce the concentration of VFAs and other chemicals so that the
buffer is restored, raising the pH of the fluid leaving the unit.
In one embodiment, the VFAs removed from the fermentation are
converted to carbon dioxide and methane by the known technology of
biogas fermentation using methanogenic microbes. In one embodiment
this takes place in a biogas generator. In one embodiment, the
removed chemicals are separated in the chemical separation unit
using an ion exchange technology. The ion exchange technology can
include, for example, the use of an anion exchange matrix known to
those of skill in the art to bind and recover carboxylic acids such
as, for example, the VFAs in the fermentation broth. In one example
the anion exchange matrix is a fluidized bed anion exchange matrix.
For example, in one embodiment acetic acid is separated from other
VFAs, and the acetic acid is shunted to the biogas generator for
biogas fermentation as described above. Other technologies may be
employed in this unit as new processes surpass the economies of
biogas processes.
[0149] Unit 6, Water Recirculation and Reclaim.
[0150] This unit receives the remainder flows from Units 4 & 5.
This unit will maintain the total water balance on the system,
separating and removing enough water from the remainder flows to
balance the water entering the system in the feedstock. The core
device in this unit is a reverse osmosis type membrane that is
capable of separating the buffer salts from water. The buffer salts
are concentrated and recycled within the process, remaining in the
flow returned to Unit 1. The reclaimed water that passes the
membrane will be expelled from the system and can be used for other
purposes outside the system.
EXAMPLES
Example 1
[0151] The processing of fruits and vegetable into food for human
consumption produces a large quantity of byproduct organic waste
that is rated "feed grade" and fit for animal consumption. The MEF
process described herein can be utilized to convert the
carbohydrates and cellulose into protein and provide reclaimed
water to the host facility. The MEF process will reduce the mass of
material to be transported as animal feed by 70% to 95%,
significantly reducing transportation costs. The diagram of this
process is shown in FIG. 9.
[0152] To produce High Protein Animal Feed (HPAF) from fruit and
vegetable processing scraps, the MEF process will be used and
supplemented by two additional processes. The chemicals would be
removed in a biogas generator and the subsequent methane used to
provide power and heat for operating the process. The biomass
material would be dewatered, pelletized and dried to a moisture
level expected in the trade, typically 12%. This material would
have the size and texture of dry pet food to minimize dust losses
and provide the expected mixing properties for the trade.
[0153] The biogas generator can be any of several commercial units
capable of converting VFAs into methane using the methanogenic
archaea or other methanogenic bacteria. A commercial upflow
anaerobic sludge blanket (UASB) reactor is expected to provide the
highest rate of gas production for the size equipment required.
These units are also provide adequate clarification for the liquid
entering the water recycle and recovery unit.
[0154] The Unit 4 biomass separation unit in this example could be
assembled from commercial equipment. The first step would be a belt
press or similar device to increase the solids content of the
biomass from 5% up to approximately 20% to 30%. The second step in
this unit is a pelletizing unit as used for cereal or pet food,
followed by a hot air dryer to reduce the moisture content of the
pellets to the desired level.
Example 2
[0155] A second product can be manufactured from the feed grade
material using the same equipment train as shown in FIG. 9. By
removing the biomass at a point in the process before it has been
fully dried or denatured, it forms a separate product that can be
utilized as a flavoring agent in animal feed. Certain species are
attracted to this microbial mixture and this agent will improve
palatability of other foods in the animal's diet. Observation has
shown that dogs are strongly attracted to this material as it is
removed from the reactor.
Example 3
[0156] There are many industrial and municipal processes that
produce a large quantity of adulterated organic wastes that are not
acceptable for any product sold for animal consumption. These
organic waste sources may include beef slaughterhouse wastes, the
organic fraction of municipal solid waste (OF-MSW), sewage sludge,
paper mill sludge, cotton gin waste and other sources. These
feedstocks can be utilized to produce a dried and pelletized
fertilizer with high levels of organics, nitrates and phosphates
(FIG. 10). The MEF process described herein can be utilized to
convert the carbohydrates and cellulose into protein and provide
reclaimed water to the host facility. The MEF process will reduce
the mass of material to be transported as fertilizer by 80% to 95%,
significantly reducing transportation costs. This fertilizer
material can be manufactured on similar equipment to the HPAF train
shown in FIG. 9, and delivered in a slow release pelletized
form.
Example 4
[0157] A second product can be manufactured from the adulterated
feedstock material using the same equipment train as the dry
fertilizer shown in FIG. 10. By removing the biomass at a point in
the process before it has been fully dewatered or denatured, the
MEF can produce a liquid material with many living microbes to
supplement the microbes that are found natively in soils (FIG. 11).
Literature notes that many of the microbes found in rumen are also
found in healthy soils, and often consumed by the ruminant while
grazing. (Hungate, 1966) Observations have shown that liquid MEF
biomass slurries are effective in stimulating plant growth. The
method of extraction and delivery of these living microbes to the
soil at a depth to minimize oxygen contact will require handling
techniques that preserve the microbes in a live state.
[0158] The use of a liquid injection system on the farm allows the
delivery of anaerobic microbes in a live condition, to re-inoculate
soils that have had their endogenous microbes depleted. This
equipment would be similar to that used today for liquid ammonia
incorporation into agricultural soils.
Example 5
[0159] Processing of adulterated organics into biomass that is
subsequently separated into separate species of protein materials
using a cascade extraction devices as shown in FIG. 12. The
material supplied to this unit would be the wet biomass fraction
typically sent to Unit #4, biomass dewatering, consisting of or
comprising the cells plus the proteins, enzymes and amino acids not
incorporated into the cells. This process may be installed at
specific MEF sites or at a Central Facility serving may RCUs.
[0160] The process consists or comprises of a series of coarse
filter elements into which have been incorporated functional sites
with specific chemicals capable of bonding to specific proteins.
There may be a large number of these filter elements in the train,
where each element is functionalized to remove a separate protein
species or protein family.
[0161] FIGS. 13 and 14 illustrate a flow diagram for one or more
processes or methods according to one or more embodiments disclosed
herein.
Example 6
Managed Ecosystem Fermentation (MEF) with Catering Waste as
Feedstock
[0162] A MEF system was established by inoculating a feedstock of
catering waste obtained from a local restaurant with rumen from a
cannulated cow fed on a dairy diet for dry cows. This experiment
demonstrates the ability of the rumen material to break down the
catering waste feedstock into chemical products including volatile
fatty acids (VFAs) and biomass for a culture period of over 100
days in a non-sterile system at 39.degree. C. and close to
atmospheric pressure. This experiment demonstrates the robustness
and stability of the MEF for continuous production of chemical
products and biomass.
[0163] The catering waste was obtained as a random sampling of
scraps and collected in 5 gallon batches. The catering waste was
ground in a blender to a maximum particle size of about 1/8.sup.th
inch in diameter and stored outside in a bucket with a non-sealing
lid. No attempt was made to keep the catering waste feedstock
sealed or sterile. The bovine rumen was from a cannulated cow fed
on a dairy diet for dry cows and the rumen was obtained with little
of the floating mat found inside the rumen organ. The rumen was
stored as an active culture in an incubator at 39.degree. C. for
over 100 days with regular removal of material, dilution with
artificial saliva (prepared as described on page 167 of Hungate,
1966, The Rumen and Its Microbes, Academic Press, New York), and
fed on a diet of alfalfa and timothy hay compressed into pellets
(sold commercially in pet stores as rabbit food).
[0164] The MEF was performed using the following materials and
methods. The MEF was carried out in a 1 gallon (3.8 L) glass
container having a metal top attached by screw threads molded into
the glass. Three liters of fermentation liquid was placed in the
glass container. The fermentation liquid was prepared by mixing
(approx. 450 ml) of the ground catering waste with (approx. 1
liter) of artificial saliva prepared as described above. The
fermentation liquid was placed in the fermentation container and
inoculated with 500 ml of the bovine rumen. The top of the
fermentation container was modified to provide a vent tube (1/4
inch poly tubing) and a plastic film rupture disk, set to a relief
pressure of approximately 20 inches of water. The other end of the
vent tube was submerged into a jar of ammonia water to apply a back
pressure on the jar of approximately 3 inches and also provide odor
control by neutralizing the carboxylic acid vapors produced by the
fermentation. The MEF was carried out in a constant temperature
model 818 Dual Program Illuminated Incubator maintained at
39.degree. C. (+/-0.5.degree. C.) (PRECISION, THERMOFISHER).
[0165] The MEF was maintained on a 24 hour cycle using a daily
process of removal of material and feeding. Material was extracted
from the MEF container using a vacuum system as follows. An
extraction nozzle was manufactured from 1/2 inch PVC pipe, with a
vent hole for operator control of the extraction rate. The
collection hose was manufactured from a nominal 1 inch flexible
hose with molded rubber end fittings. The end fittings were
modified to connect to the 1/2 inch PVC nozzles and 3/4 inch PVC
collection hose fitting on the extraction receiver tank. The
extraction receiver tank was manufactured from a 5 gallon plastic
bucket with resealable lid. The lid was modified with the addition
of 1) a vacuum supply fitting (1/4 inch threaded tube bulkhead
fitting) for connecting the receiver tank to the vacuum pump
assembly; 2) a collection hose fitting (3/4 inch PVC pipe bulkhead
fitting and hose slip connection) for connecting the collection
hose; and 3) a vacuum regulator to limit the vacuum within the
extraction vessel to a value that will not collapse the vessel, but
still allow for sufficient suction to withdraw the MEF materials
from the fermentation vessel. The vacuum pump was a standard dental
vacuum pump, model 5711-130, manufactured by (SCHUCO, Williston
Park, N.Y.). An on-off switch assembly has been provided for
operator convenience.
[0166] Observation of the fermentation culture showed formation of
a mat of material at the top of the culture, a liquid layer below
the mat, and a layer of settled material at the bottom. The mat
material contained both organic matter and lipid material. Each
day, the pH of the MEF was measured and a sample of the liquid
layer was removed for analysis by gas chromatography (GC). The pH
was measured by inserting a pH probe (ORION Model 420A with a
YSI-110-1 pH probe) through the mat at the top of the fermentation
culture into the liquid layer below. The pH meter was calibrated
using a pH 10.0 and pH 4.0 standard to provide a two point
calibration and verified with a pH 7.0 standard. The sample for GC
analysis was obtained by inserting a Pasteur pipette through the
top mat of the culture and withdrawing 1.5 ml of the liquid below
to a clean sample tube, acidifying with 2 drops of muricatic acid,
and sealing the tube. Next, the MEF was maintained by removing
about 1/3 of the total fermentation culture. About 1/3 of each of
the mat, the liquid layer, and the settled bottom layer was
separately removed. Removal of the liquid and bottom portions was
performed by aspiration and removal of the top mat portion was
performed by scooping with a spatula. About 500 ml of the catering
waste feedstock and about 500 ml of the artificial saliva was then
added back to the fermentation. The pH was again measured and
recorded. The fermentation was sparged with CO.sub.2 using a wand
for about 10 seconds with the CO.sub.2 regulator set at 5 psi. The
lid of the fermentation container was reinstalled and the gas vent
tube connecting the bulkhead fitting in the lid to the jar of
ammonia water was attached.
[0167] The fermentation activity by the MEF was determined by GC
analysis. The liquid layer that was sampled from the MEF on a daily
basis as described above was tested by GC for the presence of
chemicals including acetic acid, proprionic acid, isobutyric acid,
butyric acid, isovaleric acid, valeric acid, lactic acid, hexanoic
acid and glycerol. The samples from the liquid layer of the MEF
were run on a HP 5890 Series II gas chromatograph with FID
detector. The column was a RESTEK MXT-WAXDA 30 m.times.0.53 mm
ID.times.1.00 um df, having maximum operating temperature of
240.degree. C. The temperature program used was initial 40.degree.
C., hold for 2 min, ramp 10.degree. C./min to 220.degree. C., hold
for 1 min at 220.degree. C. The GC/FID was attached to a SRI Model
202 PEAKSIMPLE CHROMATOGRAPHY DATA SYSTEM controlled via a serial
connection to a PC. The PC used PEAKSIMPLE 3.85 software (SRI
INSTRUMENTS) for calibration and data processing. Peak position and
area calibration was done using a 4 point method on standard
solutions of known concentrations of methanol, acetone, ethanol,
butanol, acetic acid, proprionic acid, isobutyric acid, butyric
acid, isovaleric acid, valeric acid, hexanoic acid, and lactic
acid. Experiments were analyzed using these calibrations. Data
analysis was performed using OPEN OFFICE CALC and ORIGIN 7.5
software (ORIGINLAB, Inc.).
[0168] FIG. 15 is a graph showing the presence and daily
fluctuation (over a 30 day period) in the liquid layer of the MEF
of each of the VFAs: acetic acid, butyric acid, valeric acid, and
hexanoic acid as a percent, as well as the percent total of these 4
VFAs. FIG. 16 is a graph showing the daily fluctuation in pH
(circle symbols) and percent total of the 4 VFAs acetic acid,
butyric acid, valeric acid, and hexanoic (square symbols) measured
in the liquid layer of the MEF over a 30 day period. These data
demonstrate that the MEF was robust enough to withstand the wide
swings in pH that occurred in the fermentation.
Example 7
Effect of pH on Chemical Production in Managed Ecosystem
Fermentation (MEF)
[0169] This experiment was performed to determine the effect
controlling the pH of the MEF on the production of chemicals
including VFAs. The MEF was established and maintained as described
above in Example 6. The change in daily procedure in this MEF was
the adjustment of final pH after feeding by the addition of sodium
bicarbonate to the MEF culture in an amount sufficient to raise the
pH to a value of 5.9 to 6.1. FIG. 17 is a graph showing the daily
percent of each of the VFAs acetic acid, butyric acid, valeric
acid, and hexanoic acid as well as the daily percent of the total
of these 4 VFAs for the MEF described above with daily pH
adjustment within a range 5.9-6.1. The data in FIG. 17 show that
adjusting the pH of the MEF each day to within a range of 5.9-6.1
resulted in an increased yield of VFAs.
Example 8
Biodiesel Waste as Feedstock for Managed Ecosystem Fermentation
(MEF)
[0170] In this experiment an MEF was used to convert the process
waste fluid from biodiesel manufacturing to chemicals including
VFAs and biomass. Biodiesel waste is primarily glycerol and also
includes carbohydrates, lipids, triglycerides, and a significant
amount of methanol. The biodiesel waste for this experiment was
obtained from a local biodiesel manufacturing plant for which it is
a waste product and potentially a disposal problem. This material
was a thick black liquid, with viscosity somewhat less than plain
glycerol. The biodiesel waste material was stored in 1 gallon
plastic jugs, with no environmental controls prior to addition to
the MEF as a feedstock.
[0171] It was first determined in a control experiment that the MEF
according to Example 6 was capable of producing VFAs when reagent
grade glycerol was added to the feedstock. The addition of reagent
grade glycerol resulted in increased fermentation activity and gas
generation, as well as increased VFA production with total
consumption of the glycerol as shown in the GC runs (data not
shown). For the experiment with added biodiesel waste, the MEF was
established and maintained as described in Example 6 except that
100 ml of biodiesel waste was added each day to the MEF. The liquid
phase of the MEF was sampled each day as described in Example 6 and
analyzed by GC. The impact of the methanol in the biodiesel waste
became apparent when the concentration of the methanol rose above
about 2%. This high level of methanol appeared to harm the MEF and
most VFA concentrations were greatly diminished for several days.
FIG. 18 is a graph showing percent of total VFA in a control MEF
and an MEF with added biodiesel waste, where the MEF with added
biodiesel waste is represented by the line with squares and the
control MEF is represented with triangles. As a result of the
observed decrease in VFA production, the amount of biodiesel waste
added to the MEF each day was reduced to 10 ml. After several days
at this reduced level of biodiesel waste, the MEF recovered and the
VFA concentrations were restored, but then the methanol levels
again exceeded 2% and the VFA concentrations decreased (see FIG. 18
between days 12 and 30).
Example 9
Addition of Clostridium acetobutylicium to Managed Ecosystem
Fermentation (MEF)
[0172] In this experiment, additional bacteria were added to the
MEF. In this case the bacterial strain, Clostridium
acetobutylicium, a butyric acid producing bacteria, was added to
the MEF to determine if total butyric acid production could be
increased without negatively affecting the stability and robustness
of the MEF. C. acetobutylicum was originally purchased from
CAROLINA BIOLOGICAL SUPPLY, INC (Burlington, N.C.) and was cultured
from spores on sterilized corn meal, according to the procedures
developed by the Commercial Solvents Corporation (Butanol and
Acetone from Corn, DH Killiffer, Industrial and Engineering
Chemistry, vol 19, No 1, 1927). A MEF with added C. acetobutylicum
was established by adding 500 ml of the culture of the C.
acetobutylicum and was otherwise treated as the MEF in Example 6. A
MEF established and maintained according to Example 6 was performed
as a control experiment. The MEF cultures were maintained for a
period of at least 30 days, and no significant changes in the
stability or robustness of the MEF with the added C. acetobutylicum
was observed. The percent production of the VFAs acetic acid,
butyric acid, valeric acid, and hexanoic in the control MEF and the
MEF with added C. acetobutylicum are shown in Table 3 below. The
addition of C. acetobutylicum to the MEF resulted in more stable
operation than the control fermentation in terms of pH and VFA
production. The 45 day average amount of total acids produced per
unit fermentation volume appeared to be about 8% higher with the
addition of the C. acetobutylicum bacteria; however, there is a
shift of about 15% from acetic acid to valeric and hexanoic acids,
as measured by daily samples on the gas chromatograph.
TABLE-US-00003 TABLE 3 Comparison of Control MEF and MEF with added
Clostridium acetobutylicum (45 day average) Acetic Butyric Valeric
Hexanoic Total acid Acid acid Acid VFA Control MEF 0.27% 0.59%
0.20% 0.20% 1.29% Plus C. 0.23% 0.56% 0.21% 0.22% 1.39%
acetobutylicum Percent -15% .sup. -5% .sup. +5% +10% .sup. +8%
Difference
Example 10
Variation of Feedstock in Managed Ecosystem Fermentation (MEF)
[0173] The experiments presented below are examples of modifying
the feedstocks in MEF. It was observed that addition of ammonia to
a MEF resulted in a visibly significant increase in the rate of
fermentation. As a result, experiments are described using daily
addition of ammonia and various feedstocks.
[0174] An experiment was performed where a MEF was established and
maintained according to Example 6 (i.e. the feedstock was catering
waste which is a high nitrogen feedstock) except that 20 ml of
household ammonia, with a concentration of about 8% NH.sub.3, was
added to the MEF on a daily basis. This experiment was performed to
determine if addition of a nitrogen source to a MEF that was
already being cultured on a high nitrogen feedstock would further
increase VFA production. The data in Table 4 below show the effect
on the percent of each of the VFAs acetic acid, butyric acid,
valeric acid and hexanoic acid produced for this MEF receiving
addition of ammonia relative to a control MEF established and
maintained according to Example 6. The data in Table 4 demonstrate
that addition of ammonia to the MEF resulted in a significant
increase in overall acid production, with the major gains in acetic
and hexanoic acids.
TABLE-US-00004 TABLE 4 Comparison of Control MEF and MEF with Daily
Addition of Ammonia Acetic Butyric Valeric Hexanoic Total acid Acid
acid Acid VFA Control MEF 0.27% 0.59% 0.20% 0.20% 1.29% Plus Daily
0.41% 0.63% 0.20% 0.28% 1.63% Ammonia Percent +52% .sup. +7% 0.00%
+40% +26% Difference
[0175] In the following experiment an MEF is established and
maintained on a combination of the high nitrogen feedstock catering
waste and the high carbon/low nitrogen feedstock wood pulp. In
addition, ammonia is added to the MEF on a daily basis. More
specifically, the MEF is established and maintained as described in
Example 6 except that the feedstock is a combination of catering
waste and wood pulp at a ratio of about 90:10 and, in addition, the
MEF is supplemented with 20 ml of household ammonia on a daily
basis as described in this Example above.
[0176] In the following experiment, a MEF is established and
maintained except that a combination feedstock comprising catering
waste and low nitrogen shredded newspaper is utilized as the
feedstock for the MEF. More specifically, a MEF is established and
maintained as described in Example 6 except that the feedstock is a
combination of catering waste and shredded newspaper at a ratio of
about 90:10 and, in addition, the MEF is supplemented with 20 ml of
household ammonia on a daily basis as described in this Example
above.
[0177] In the following experiment, a MEF is established using a
combination feedstock where each of the feedstock components lacks
either sufficient nitrogen or sufficient carbon on its own to
maintain the MEF. Specifically, in this experiment a MEF is
established and maintained as described in Example 6 except that
the feedstock is a mixture of about 10% low carbon/high nitrogen
sewage sludge and about 90% high carbon/low nitrogen municipal
waste.
Example 11
Rumen Variation in Managed Ecosystem Fermentation (MEF)
[0178] The following experiments describe MEFs established using
rumen from different animals or combinations of different
rumens.
[0179] In this experiment, a MEF was established and maintained as
described in Example 6 except that the bovine rumen was replaced
with sheep rumen. For this experiment, initially 60 ml of sheep
rumen was obtained from a veterinarian and cultured over several
days as described above for the bovine rumen in Example 6 to a
volume of greater than a gallon. At that point, an MEF was
established and maintained as described above in Example 6. The use
of sheep rumen proved reliable, but with lower overall acid yields.
The one increase was measured in acetic acid production.
TABLE-US-00005 TABLE 5 Comparison of Control MEF and MEF of Sheep
Rumen Acetic Butyric Valeric Hexanoic Total acid Acid acid acid VFA
Control MEF 0.27% 0.59% 0.20% 0.20% 1.29% MEF of Sheep 0.41% 0.30%
0.13% 0.10% 1.05% Rumen Percent +52% -49% -35.00% -50% -20%
Difference
[0180] In this experiment, a combination of bovine rumen and sheep
rumen was used in a MEF. For this experiment, a new MEF was
established and maintained as described in Example 6 except that
750 ml each of bovine rumen and the sheep rumen grown in an MEF was
used with 1 liter of artificial saliva to establish the new MEF.
Table 7 below shows a comparison of VFA production by the control
MEF and the MEF established with equal amounts of bovine and sheep
rumen. The inclusion of the sheep rumen in the MEF resulted in a
decrease in the average total VFAs produced by the fermentation.
While the acetic acid increased, the other significant acid
production levels decreased on the catering waste feedstock.
TABLE-US-00006 TABLE 6 Comparison of Control MEF and MEF with
Bovine/Sheep Rumen Blend Acetic Butyric Valeric Hexanoic Total Acid
Acid Acid Acid VFA Control MEF 0.27% 0.59% 0.20% 0.20% 1.29% Bovine
Plus 0.41% 0.30% 0.12% 0.12% 1.03% Sheep Percent .sup. 52% -49%
-40% -40% -20% Difference
[0181] In this experiment, a MEF is established and maintained in
which the rumen is supplemented with ground earth worms to provide
earth worm microbes to the MEF based on the use of vermiculture for
composting. Specifically, a MEF is established and maintained
according to Example 6 except that 1 liter of freshly ground earth
worms is included with the addition of the rumen at the
establishment of the MEF.
[0182] In this experiment, a MEF is established and maintained in
which the rumen is supplemented with ground termites to provide
termite microbes to the MEF based on the use of cellulase enzymes
from termites to break down cellulose (Tokuda & Watanabe,
2007). Specifically, a MEF is established and maintained according
to Example 6 except that 1 liter of freshly ground termites is
included with the addition of the rumen at the establishment of the
MEF.
[0183] The following references are hereby incorporated in their
entirety: [0184] Adenije, A A, Jimoh, A, "Effects of Replacing
Maize with Enzyme Supplemented Bovine Rumen Content in the Diets of
Pullet Chicks" International Journal of Poultry Science 6 (11):
814-817, 2007. [0185] Bata, Lasztity, "Detoxification of
mycotoxin--contaminated food and feed by microorganisms," Trends in
Food Science & Technology 10, 223-228, 1999. [0186] Brooker,
"Tannins in Livestock and Human Nutrition," ACIAR Proceedings No.
92, 2005
http://www.smallstock.info/reference/ACIAR/Tannins/PR92-Part1.pdf]
(compilation of related papers). [0187] Brooker, "Rumen
microorganisms as providers of high quality protein," Livestock
Research for Rural Development, Vol. 6, No. 3, March 1995.
http://www.lrrd.org/lrrd6/3/1.htm [0188] Calt, E., "Island
Financial Resource Impacts from Managed Ecosystem Fermentations for
the Treatment of Organic Waste Streams," IEA Conference," 2011.
[0189] Feitshans, "Federal Regulation of Industrial Biotechnology
in the United States, IEA Conference," 2011. [0190] Gregg,
"Biological world-first for Rumen Biotech Group," Synergy, Vol. 2,
No. 2, Winter, 1998,
http://wwwcomm.murdoch.edu.au/synergy/9802/rumen.html. [0191]
Hungate, R E, "The Rumen and Its Microbes." Academic Press, New
York, 1966. [0192] Hungate, R E, "The Rumen Microbial Ecosystem,"
Annual Review of Ecology and Systematics, Vol. 6, pp. 39-66, 1975.
Stable URL: http://www.jstor.org/stable/2096824 [0193] Sauvant,
"Modeling Rumen Carbon Partitioning", Bovidig database, 2009,
https://colloque2.inra.fr/ . . . /content/ . . .
/Sauvant_ModRu.sub.--7Modnutpres.pdf. [0194] Tokuda & Watanabe,
Biol. Lett. 3: 336-339, 2007. [0195] Weimer, "Manipulating Ruminal
Fermentation: A Microbial Ecological Perspective," J. Anim. Sci.
76:3114-3122, 1998.
* * * * *
References